Internal air separators in a dirt separation device

ABSTRACT

A vacuum cleaner includes a body having a canister assembly and a nozzle assembly including a suction inlet. A suction generator is carried on the body. In addition a dirt collection vessel is carried on the body. The dirt collection vessel includes a cyclonic separator having a cylindrical sidewall, a tangentially directed inlet and an axially directed outlet. The dirt collection vessel is characterized by a compound airflow guide provided adjacent the axially directed outlet. The compound airflow guide includes a blade portion and a frustoconical portion.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to the floor care equipment field and, more particularly, to a highly efficient and effective vacuum cleaner incorporating a cyclonic separator having a compound air flow guide to enhance cleaning efficiency.

BACKGROUND OF THE INVENTION

Cyclonic vacuum cleaners have long been known in the art. Such vacuum cleaners remove dirt and debris from the air stream by means of vortex separation. Specifically, a high speed rotating air flow is established within a cylindrical chamber often referred to as a cyclone. Air flows in a spiral pattern before exiting the cyclone through an axially directed outlet. Rotational effects, centrifugal force and gravity all function to separate dirt and debris from the air stream. Specifically larger particles in the rotating stream have too much inertia to follow the tight curve of the stream. Such particles strike the outer wall of the cyclone falling to the bottom of the cyclone where they are collected or removed. The relatively clean air is then drawn through the axially directed outlet.

The present invention relates to a vacuum cleaner incorporating a new and improved dirt collection vessel having a cyclonic separator equipped with a compound air flow guide to better direct air flow and provide enhanced cleaning efficiency.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a vacuum cleaner is provided comprising a body including a canister assembly and a nozzle assembly. The nozzle assembly includes a suction inlet. A suction generator is carried on the body. A dirt collection vessel is also carried on the body. The dirt collection vessel includes a cyclonic separator having a cylindrical side wall, a tangentially directed inlet and an axially directed outlet. The dirt collection vessel is characterized by a compound air flow guide adjacent the axially directed outlet. The compound air flow guide includes a blade portion and a frustoconical portion.

The blade portion is provided between the frustoconical portion and the axially directed outlet. The blade portion provides multiple feed channels in communication with the axially directed outlet. The blade portion has a substantially +-shaped cross section. The frustoconical portion converges toward the blade portion. The frustoconical portion includes a closed concavity. More specifically describing the invention the axially directed outlet is defined by a conduit and the blade portion of the compound air flow guide includes multiple notches that engage that conduit.

In accordance with yet another aspect of the present invention a method is provided of guiding air flow through a cyclonic separator wherein that cyclonic separator includes a cylindrical sidewall and an axially directed outlet. The method comprises the steps of: (a) providing a compound air flow guide in the cyclonic separator adjacent the outlet, (b) moving air over a frustoconical surface of the compound air flow guide so as to provide cyclonic air flow and (c) moving the air through channels defined by a blade portion of the compound air flow guide so as to redirect that air into the axially directed outlet. In addition, the method includes the step of dissipating the cyclonic flow of the air as the air is fed into the axially directed outlet.

In accordance with yet another aspect of the present invention, a vacuum cleaner comprises a body including a canister assembly and a nozzle assembly. The nozzle assembly includes a suction inlet. Both a suction generator and dirt collection vessel are carried on the body. The dirt collection vessel includes a cyclonic separator having a primary cyclone and at least one secondary cyclone. The primary cyclone has a primary dirt collection chamber including a first cylindrical sidewall, a first tangentially directed inlet and a first axially directed outlet. The at least one secondary cyclone includes a dirt separation chamber having a second cylindrical side wall, a second tangentially directed inlet and a second axially directed outlet. A compound air flow guide is provided adjacent the second axially directed outlet. The compound air flow guide includes a blade portion and frustoconical portion.

In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is a left side elevational view of a vacuum cleaner incorporating the novel dirt collection vessel of the present invention;

FIG. 2 is an exploded perspective view of the dirt collection vessel;

FIG. 3 is a cross sectional view illustrating the dirt collection vessel of the present invention and the air flow through that vessel;

FIG. 4 is a detailed perspective view of a compound air flow guide of the type provided in the dirt collection vessel of the present invention;

FIG. 5 is a detailed cross sectional view through the conduit forming the axial outlet of the secondary cyclone, looking toward the compound air flow guide; and

FIG. 6 is a cross-sectional view of an alternative embodiment of the dirt collection vessel of the present invention.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Reference is now made to FIG. 1 illustrating an upright vacuum cleaner 10 of the present invention. While an upright vacuum cleaner 10 is illustrated, it should be appreciated that the present invention is not limited to upright vacuum cleaners but instead covers any type of vacuum cleaner incorporating the novel dirt collection vessel 12 of the present invention. This includes, but is not limited to, canister vacuum cleaners.

The vacuum cleaner 10 includes a body, generally designated by reference numeral 14. The body 14 includes a nozzle assembly 16 and a control assembly 18. As is known in the art, the control assembly 18 is pivotally connected to the nozzle assembly 16 to aid the operator in manipulating the vacuum cleaner 10 back and forth across the floor. Wheels 19 carried on the body 14 allow the vacuum cleaner 10 to be moved smoothly across the floor. As illustrated, the nozzle assembly 16 is equipped with a suction inlet 20. A rotary agitator 22, including bristle tufts, wipers or cleaning ribs 23, is mounted on the nozzle assembly 16 and extends across the suction inlet 20. The rotary agitator 22 rotates relative to the nozzle assembly 16 in a manner well known in the art.

The control assembly 18 carries a suction generator 28 (i.e. a fan and motor assembly) and the dirt collection vessel 12. The details of the dirt collection vessel 12 will be described in greater detail below. The control assembly 18 also includes a control stalk 30 and an actuator switch (not shown) for turning the vacuum cleaner 10 on and off. The vacuum cleaner 10 may be powered by electricity from an electrical wall outlet through a power cord (not shown) and/or by means of an onboard battery.

In operation, the rotary agitator 22 quietly and efficiently brushes dirt and debris from the nap of an underlying carpet. That loosened dirt and debris is first drawn into the suction inlet 20 before being delivered to the dirt collection vessel 12 by means of the suction generator 28. Dirt and debris is trapped in the dirt collection vessel 12 and the now clean air is directed over the motor of the suction generator 28 to provide cooling before being exhausted back into the environment through the exhaust vent or port 34.

As best illustrated in FIGS. 2 and 3, the dirt collection vessel 12 includes a primary cyclone 40 having a first cylindrical side wall 42 and a bottom wall 44. In one possible embodiment the bottom wall 44 is connected by means of a hinge 46 and latch mechanism 48 to the side wall 42. Thus, the bottom wall 44 may be pivoted open to allow emptying of the primary dirt collection chamber 50 provided inside the side wall 42. A seal 52 is provided between the bottom wall 44 and the side wall 42.

The primary cyclone 40 also includes a first tangentially directed inlet 54. A shroud 56, concentrically received within the side wall 42, includes an upper lip 58, a lower lip 60 and a side wall 62 including a series of perforations or openings. Upper lip 58 defines an axially directed outlet of the primary cyclone 40.

The dirt collection vessel 12 also includes an inner wall 64 that is concentrically received within the shroud 56 and the first cylindrical sidewall 42. The lower end of the inner wall 64 is connected to the bottom wall or door 44 by a connector 66. The upper end of the inner wall 64 incorporates a collector 68. The collector 68 forms a base for supporting an inner secondary cyclone assembly 70.

The secondary cyclone assembly 70 includes a substantially star shaped support 72 including a series of indented sidewalls 74, a concentrically located air diverter 76 and five radially arrayed apertures 78. A partition 80 rests on the support 72 and includes a central opening 82. An inner secondary cyclone housing 84 includes five secondary cyclones 86.

As illustrated, the inner secondary cyclone housing 84 is held in the central opening 82 of the partition 80. Fasteners 88 secure the support 72, partition 80 and inner secondary cyclone housing 84 together. Specifically, the fasteners 88 threadedly engage the bosses 90 provided on the inner secondary housing 84.

As illustrated, each of the secondary cyclones 86 includes a dirt separation chamber 92 having a second cylindrical sidewall 94 and a second tangentially directed inlet 96. The bottom of each secondary cyclone 86 includes a dirt particle discharge outlet 98. Each such outlet 98 is aligned with and received in one of the five apertures 78 provided in the support 72.

An air stream distributor 100 is received and held on the inner secondary cyclone housing 84. The air distributor 100 includes a central opening 102 and five radially arrayed channels 104. One channel 104 communicates with each second tangentially directed inlet 96 of the secondary cyclones 86. An outer secondary cyclone housing 106 includes a top wall 108 for closing the tops of the secondary cyclones 86 and a downwardly directed flange 110 received over and around the inner secondary cyclone housing 84. The lower lip 112 of the flange 110 engages the partition 80 and the top edge of the side wall 42. A series of five radially arrayed conduits 114 are provided in the top wall 108 and define the second axially directed outlets 116 of each of the secondary cyclones 86.

A top 118 is secured on the outer secondary cyclone housing 106. A seal 120 is provided between the top 118 and the outer secondary cyclone housing 106 to seal the discharge manifold 122 defined between the top 118 and the top wall 108 of the outer secondary cyclone housing 106. A discharge outlet 124 is provided in the top 118. In one possible embodiment a handle 126 is pivotally connected to the top 118. The handle 126 may be used by an operator to conveniently lift and hold the dirt collection vessel 12 when it is removed from the vacuum cleaner 10.

A compound air flow guide, generally designated by reference numeral 126 is provided in each secondary cyclone 86. As best illustrated in FIGS. 2-4, each compound air flow guide 126 includes a blade portion 128 and a frustoconical portion 130. The blade portion 128 is provided between the frustoconical portion 130 and the second axially directed outlet 116 of each secondary cyclone 86. As best illustrated in FIG. 5, each blade portion 128 provides multiple feed channels 132. Thus, where the blade portion has a substantially +-shaped cross section four feed channels 132 are provided for feeding the air stream into the associated conduit 114. As best illustrated in FIGS. 3 and 4, each blade portion 128 includes a series of notches 134 that engage the conduit 114 at the end of the conduit opposite the axially directed outlet 116. A permanent adhesive may be utilized to secure the compound air flow guides 126 on the conduits 114 in the secondary cyclones 86. As further illustrated in FIG. 3, each frustoconical portion 130 includes a closed concavity 136 at the bottom thereof that converges toward the blade portion 128.

The operation of the vacuum cleaner will now be described in detail. During vacuum cleaner operation the rotary agitator 22 beats dirt and debris from the nap of an underlying carpet being cleaned. Simultaneously, the suction generator 28 draws an air stream, entraining that dirt and debris, through the suction inlet 20. The air stream, dirt and debris are then conveyed by duct work (not shown) through the tangentially directed inlet 42 of the primary cyclone 40. The air stream with entrained dirt and debris then moves in a cyclonic air flow pattern through the dirt collection chamber 50 (note action arrows A). This air flow pattern creates centrifugal forces that force dirt and debris in the air stream outwardly toward the side wall 42. That dirt and debris then gradually falls downwardly toward the bottom of the primary dirt collection chamber 50 where it collects. Relatively clean air is then drawn through the apertures in the side wall 62 of the shroud 56 and through the axially directed outlet formed by the upper lip 58 (see action arrow B). The air stream is then drawn past the indented side walls 74 of the support 72 and then over the top of the support and along the air diverter 76 upwardly between the secondary cyclones 86 (see action arrow C).

More specifically, the partition seals 80 around the secondary cyclones 86 and along the flange 110 forcing the air stream to then pass through the aperture 82. The air streams then travels between the secondary cyclones 86 through the central opening 102 in the air distributor 100. The air distributor 100 divides the air stream in five ways as the air stream is directed through the channels 104 to each of the tangentially directed inlets 96 of the secondary cyclones 86 (see action arrow D). The air stream then moves in a cyclonic air flow pattern through the dirt separation chambers 92 of the secondary cyclones 86. During this process, the air stream then flows over and around the frustoconical surface of the frustoconical portion 130 of the compound air flow guides 126. The frustoconical surface promotes smooth non-turbulent flow so that fine particles move efficiently under centrifugal force into engagement with the second cylindrical side walls 94. Those particles then fall downwardly through the dirt particle discharge outlets 98 into the collector 68 which serves to deliver the particles into the secondary dirt collection chamber 136 provided in the inner wall 64.

Simultaneously, the air stream, now free of fine particles, is drawn toward the axially directed outlets 116. As the air stream moves toward the conduits 114 defining the outlets 116, the air stream is redirected by the blade portions 128 of the compound air flow guides 126. As a consequence, cyclonic air flow is dissipated so that the air stream now moves more smoothly and efficiently through the conduits 114 and the axially directed outlets 116 into the discharge manifold 122. From there the air stream is discharged through the discharge outlet 124 and delivered by conduit (not shown) to the suction generator 28. The air stream then flows over the motor of the suction generator 28 to provide cooling before being exhausted through a final filter (not shown) into the environment through the exhaust vent 34.

An alternative embodiment of the present invention is illustrated in FIG. 6. This embodiment is identical to the previously described embodiment except for the fact that it does not include an air diverter 76. Otherwise, the air flow is exactly as previously described with respect to the earlier embodiment.

The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way. 

1. A vacuum cleaner, comprising: a body including a canister assembly and a nozzle assembly including a suction inlet; a suction generator carried on said body; and a dirt collection vessel carried on said body, said dirt collection vessel including a cyclonic separator having a cylindrical sidewall, a tangentially directed inlet and an axially directed outlet; said dirt collection vessel being characterized by a compound airflow guide adjacent said axially directed outlet, said compound airflow guide including a blade portion and a frustoconical portion.
 2. The vacuum cleaner of claim 1, wherein said blade portion is provided between said frustoconical portion and said axially directed outlet.
 3. The vacuum cleaner of claim 2, wherein said blade portion provides multiple feed channels in communication with said axially directed outlet.
 4. The vacuum cleaner of claim 3, wherein said blade portion has a substantially +-shaped cross section.
 5. The vacuum cleaner of claim 4, wherein said frustoconical portion converges toward said blade portion.
 6. The vacuum cleaner of claim 5, wherein said frustoconical portion includes a closed concavity.
 7. The vacuum cleaner of claim 5, wherein said axially directed outlet is defined by a conduit and said blade portion includes multiple notches that engage said conduit.
 8. A method of guiding airflow through a cyclonic separator including a cylindrical sidewall and an axially directed outlet, comprising: providing a compound airflow guide in said cyclonic separator adjacent said outlet; moving air over a frustoconical surface of said compound airflow guide so as to promote cyclonic airflow; and moving said air through channels defined by a blade portion of said compound airflow guide so as to redirect said air into said axially directed outlet.
 9. The method of claim 8, including dissipating cyclonic flow of said air as said air is fed into said axially directed outlet.
 10. A vacuum cleaner, comprising: a body including a canister assembly and a nozzle assembly including a suction inlet; a suction generator carried on said body; and a dirt collection vessel carried on said body; said dirt collection vessel including a primary cyclone and at least one secondary cyclone; said primary cyclone having a primary dirt collection chamber including a first cylindrical sidewall, a first tangentially directed inlet and a first axially directed outlet; said at least one secondary cyclone including a second dirt separation chamber having a second cylindrical sidewall, a second tangentially directed inlet, a second axially directed outlet and a compound airflow guide adjacent said second axially directed outlet, said compound airflow guide including a blade portion and a frustoconical portion.
 11. The vacuum cleaner of claim 10, wherein said blade portion is provided between said frustoconical portion and said second axially directed outlet.
 12. The vacuum cleaner of claim 11, wherein said blade portion provides multiple feed channels in communication with said second axially directed outlet.
 13. The vacuum cleaner of claim 12, wherein said blade portion has a substantially +-shaped cross section.
 14. The vacuum cleaner of claim 13, wherein said frustoconical portion converges toward said blade portion.
 15. The vacuum cleaner of claim 14, wherein said frustoconical portion includes a closed concavity.
 16. The vacuum cleaner of claim 14, wherein said second axially directed outlet is defined by a conduit and said blade portion includes multiple notches that engage said conduit.
 17. The vacuum cleaner of claim 10 further including a secondary dirt collection chamber.
 18. The vacuum cleaner of claim 17, wherein said at least one secondary cyclone includes a dirt particle discharge outlet in fluid communication with said secondary dirt collection chamber.
 19. The vacuum cleaner of claim 18, further including an inner wall concentrically received in said first cylindrical sidewall, said secondary dirt collection chamber being provided within said inner wall.
 20. The vacuum cleaner of claim 10, wherein said first axially directed outlet is upstream from said second tangentially directed inlet. 